Dismantling system

ABSTRACT

A system for dismantling a pallet includes a feed system configured to convey the pallet along a direction of travel. The feed system has a measuring station and a staging area. The measuring station is configured to obtain dimensions of the pallet. A saw is configured to dismantle the pallet. A manipulator includes a robotic arm. The manipulator is configured to move the pallet from the staging area to the saw for dismantling.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.15/599,414, filed May 18, 2017 which claims the benefit of U.S.Provisional Patent Application Ser. No. 62/338,038, filed on May 18,2016. The entire disclosures of the above patent applications are herebyincorporated herein by reference.

FIELD OF THE INVENTION

The invention relates generally to a system and method for dismantlingwooden pallets, and particularly to a method and apparatus forrobotically dismantling wooden pallets.

BACKGROUND

Since the development of the modern forklift in the early part of thetwentieth century, the wooden pallet has been relied upon as anefficient means of handling and transporting bulk goods and freight. Thewooden pallet is particularly desirable due to its relatively low costto manufacture as well as the abundance and renewability of wood.According to the U.S. Forest Service, there are approximately twobillion wooden pallets currently in circulation throughout the UnitedStates.

While the relative durability of wood makes it a desirable material forpallets, it is subject to deterioration and destruction over a period oftime. For example, individual boards forming the pallet may rot ifcontinuously exposed to moisture or may be broken during handling.Accordingly, there is a continuous need for new pallets to replacedestroyed or expended pallets and fill a growing market demand.

Although wood is a readily available resource, there are a number offactors driving a desire to maximize recovery of pallets, as opposed tocontinuously manufacturing new pallets. For example, wood used inpallets is typically treated with a preservative chemical in order tominimize decomposition. While effective in extending the life of thepallet, the preservative chemical is toxic, making disposal of palletsharmful to the environment. In addition, despite the renewable nature ofwood, the sheer volume of pallets used in the United States has furtherdriven the desire to recover as many pallets as possible in order tominimize cost and consumption.

Pallets vary in make, size, and construction. Because of theinconsistency in size and construction of pallets, pallet recovery hashistorically been a substantially manual process, requiring individualsto dismantle expended pallets using various hand tools in order tosalvage useable components. This is generally an inefficient andphysically demanding process requiring each board of a pallet to beremoved individually. Attempts to automate pallet disassembly have beenminimally successful. Many systems lack an ability to accommodatemanufacturing inconsistencies among pallets.

Accordingly, there exists a need in the art for an automated system andmethod for dismantling pallets, wherein the system is capable ofdetecting and accommodating manufacturing inconsistencies among pallets.

SUMMARY

In concordance with the instant disclosure, an automated system andmethod for dismantling pallets, wherein the system is capable ofdetecting and accommodating manufacturing inconsistencies of amongpallets.

According to an embodiment of the instant disclosure, A system fordismantling a pallet includes a feed system configured to convey thepallet along a direction of travel. The feed system has a measuringstation and a staging area. The measuring station is configured toobtain dimensions of the pallet. A saw is configured to dismantle thepallet. A manipulator includes a robotic arm. The manipulator isconfigured to move the pallet from the staging area to the saw fordismantling.

According another embodiment of the instant disclosure, a system fordismantling a pallet is disclosed. The system includes a feed systemconfigured to convey the pallets along a direction of travel. The feedsystem has a measuring station and a staging area. The measuring stationis configured to obtain dimensions of the pallet. The measuring stationincludes a first sensor unit extending in a direction substantiallyperpendicular to the direction of travel and a second sensor unitextending in a direction substantially parallel with respect to thedirection of travel. The system additionally includes a saw configuredto dismantle the pallet and a manipulator comprising a robotic arm. Themanipulator configured to move the pallets from the staging area to thesaw for dismantling.

In a further embodiment of the instant disclosure, a system fordismantling pallets is disclosed. The system includes a pallet and afeed system configured to convey the pallet along a direction of travel.The feed station has a measuring station and a staging area. Themeasuring station obtains dimensions of the pallet. The system includesa saw receiving the pallet and dismantling the pallet. The systemfurther includes a manipulator comprising a robotic arm and an end ofarm tool configured to support the pallet. The manipulator moves thepallet from the staging area to the saw for dismantling. The manipulatorreceiving values of the dimension of the pallet from the measuringstation via a controller.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top perspective view of a pallet according to according toprior art;

FIG. 2 is a bottom perspective view of the pallet of FIG. 1;

FIG. 3 is a top perspective view of a system according to an embodimentof the instant disclosure;

FIG. 4 is a top perspective view of the system of FIG. 3;

FIG. 5 is a top perspective view of a gage station of the system ofFIGS. 3-4;

FIG. 6 is a top perspective view of a flipping station of the gagestation of FIG. 5;

FIG. 7 is a top perspective view of an inverter of the flipping stationof FIG. 6;

FIG. 8 is a top perspective view of a measuring station of the gagestation of FIG. 5;

FIG. 9 is a top perspective view of a lift riser of the measuringstation of FIG. 8;

FIG. 10 is a fragmentary right perspective view of portions of sensingunits of the measuring station of FIG. 8;

FIG. 11 is a fragmentary right perspective view of the portions of thesensing units of the measuring station of FIG. 8 with a pallet shown;

FIG. 12 is a top perspective view of a staging station and a manipulatorof the system of FIGS. 3-4;

FIG. 13 is a top perspective view of an end of arm tool of themanipulator of FIG. 12;

FIG. 14 is a bottom plan view of the end of arm tool of FIG. 13;

FIG. 15 is a side elevational view of the end of arm tool of FIGS.13-14;

FIG. 16 is a bottom perspective view of the end of arm tool of FIGS.13-15, with a pallet coupled to the end of arm tool;

FIG. 17 is a top perspective view of a saw and an unloading station ofthe system of FIGS. 3-4;

FIG. 18 is a top perspective view of an accumulator positioned in aloading area of the system of FIGS. 3-4;

FIG. 19 is a top perspective view of a support member of the accumulatorof FIG. 18; and

FIGS. 20-24 are schematic illustrations showing the steps fordismantling the pallets with the saw of FIG. 17.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description and appended drawings describe andillustrate various embodiments of the invention. The description anddrawings serve to enable one skilled in the art to make and use theinvention, and are not intended to limit the scope of the invention inany manner. In respect of the methods disclosed, the steps presented areexemplary in nature, and thus, the order of the steps is not necessaryor critical. As used herein, the term “substantially” means approximateto or almost.

As shown in FIGS. 1-2, a pallet 100 as discussed herein includes a topdeck 102 and a bottom deck 104, each comprising a plurality of deckboards 106. The deck boards 106 of each of the top deck 102 and thebottom deck 104 are aligned substantially parallel to each other in afirst direction D1. The pallet 100 further includes a plurality ofstringers 108 disposed intermediate the top deck 102 and the bottom deck104. The stringers 108 are oriented transverse to the deck boards 106 ofthe top deck 102 and the bottom deck 104 in a second direction D2. Thestringers 108 include notches 109 formed thereon. A plurality of forkpockets 110 is formed intermediate adjacent ones of the stringers 108and the opposing top deck 102 and bottom deck 104. The pallets 100constructed in this manner may be provided in any size and overall shapeby changing a length and quantity of the deck boards 106 and/orstringers 108, as shown.

As shown in FIGS. 3-4, a system 22 for dismantling the wooden pallets100 includes a loading area 18, feed system 24, a manipulator 26, a saw28, and an unloading system 29, each in communication with a controller30. Generally, a plurality of the pallets 100 is provided to themanipulator 26 via the feed system 24, wherein the manipulator 26withdraws individual ones of the pallets 100 from the feed system 24,and presents the pallets 100 to the saw 28 for dismantling.

Referring to FIGS. 3-11, the feed system 24 includes a substantiallycontinuous conveyor bed 31 with a plurality of rollers 33 including agage station 32, a staging area 34, and a discharge conveyor 36. Thepallets 100 travel along the conveyor bed 31 in a direction of travelindicated by the arrow. Each of the gage station 32 and the staging area34 includes the conveyor bed 31 which may be powered, wherein therollers 33 are mechanically driven, while the discharge conveyor 36 is aportion of the conveyor bed 31 which is typically not driven, whereinthe rollers 33 are gravity fed. However, the entire conveyor bed 31 ofthe feed system 24 or portions thereof can be driven or undriven, asdesired. In the illustrated embodiment, the powered or driven portionsof the conveyor bed 31 are chain-driven line-shaft roller (CDLR)conveyors having a plurality of powered rollers, as are known in theart. However, those skilled in the art will understand that other typesof powered conveyor beds can be used.

The portion of the conveyor bed 31 comprising the gage station 32 andthe staging area 34 is oriented at an oblique angle α with respect tohorizontal, level or a support surface the feed system 24 is positionedon, wherein the conveyor bed 31 is inclined from a first side of theconveyor bed 31 to a second side of the conveyor bed 31. The inclinedorientation of the conveyor bed 31 advantageously urges the pallets 100towards a datum wall 38 formed on the first side of the conveyor bed 31as the pallets 100 move along the conveyor bed 31. As discussedhereinbelow, the datum wall 38 of the conveyor bed 31 is used to alignsides of the pallets 100 along a common side (i.e. the first side) ofthe conveyor bed 31 for measurement and retrieval. For example, thepallets 100 may vary between dimensions of 30 inches by 30 inches and 60inches by 60 inches. In order for the side of the pallets 100 to travelsubstantially parallel to the first side of the conveyor bed 31, theangle α is desired so the pallets 100 are not skewed with respect to thedirection of travel. It has been discovered the angle α of between 3degrees and 10 degrees provides favorable results, and that the angle αof 5 degrees is ideal for coaxing the pallets 100 towards the datum wall38 while moving in the direction of travel, which minimizes a lateralslip of the pallets 100 while stationary.

The feed system 24 further includes a plurality of gates 40 a, 40 b, 40c, 40 d, 40 e disposed along the conveyor bed 31. The gates 40 a, 40 b,40 c, 40 d, 40 e are configured to selectively obstruct travel of thepallets 100 along the feed system 24. In the illustrated embodiment,each of the gates 40 a, 40 b, 40 c, 40 d, 40 e is a rotatable flapextending across the width of the conveyor bed 31. The gates 40 a, 40 b,40 c, 40 d, 40 e are selectively positionable between a first positionand a second position. In the first position, the gates 40 a, 40 b, 40c, 40 d, 40 e extend outwardly from a travel surface 41 of the conveyorbed 31 to obstruct the passage of the pallets 100 therealong. In thesecond position, the gates 0 a, 40 b, 40 c, 40 d, 40 e are retractedfrom the conveyor bed 31 to allow the passage of the pallets 100thereby. The gates 40 a, 40 b, 40 c, 40 d, 40 e are mechanicallyextended to the first position or retracted to the second positiondepending on the position of the pallets 100 on the conveyor bed 31.Other means of selectively obstructing the passage of the pallets 100along the conveyor bed 31 will be appreciated by those skilled in theart.

As shown in FIGS. 5-11, the gage station 32 includes a flipping station42 and a measuring station 44. In the embodiment shown, the flippingstation 42 of the gage station 32 includes an inverter 46 and a pair ofthe gates 40 a, 40 b. Particularly, a first one of the gates 40 a isdisposed at an intermediate portion of the flipping station 42 and isconfigured to stop the pallet 100 within the inverter 46 and a secondone of the gates 40 b is disposed downstream of the inverter 46 withrespect to the direction of travel along the conveyor bed 31.

The inverter 46 includes a pair of cradles 48, including a liftingcradle 48 a and a lowering cradle 48 b. The cradles 48 are pivotallycoupled to a lift frame 57 of the inverter 46 on opposing sides of thefirst one of the gates 40 a. Thus, the lifting cradle 48 a is disposedon an upstream side of the first one of the gates 40 a with respect tothe direction of travel and the lowering cradle 48 b is disposed on adownstream side of the first one of the gates 40 a with respect to thedirection of travel. A first end 50 of each of the cradles 48 ispivotally coupled to the lift frame 57 adjacent the first one of thegates 40 a, and an opposing second end 52 is spaced from the first oneof the gates 40 a. The second end 52 pivots about the first end 50 ofeach of the cradles 48.

Each of the cradles 48 includes a plurality of cross members 54 spanninga width of the conveyor bed 31 in a direction substantiallyperpendicular to the direction of travel and forming a cradle bed forreceiving the pallets 100 thereon. On each side of the cradles 48,opposing funnel plates 56 taper outwardly from the cradle bed at thesides of the cradles 48. The funnel plates 56 are configured to guidethe pallets 100 into the pair of cradles 48.

Each of the cradles 48 is selectively positionable in a first positionand a second position. In the first position of the cradles 48, thecradles 48 are retracted and received within the conveyor bed 31 at theflipping station 42. Particularly, the cross members 54 of each of thecradles 48 are received intermediate the rollers 33 of the conveyor bed31 to allow the pallets 100 to pass along the flipping station 42 andalong the conveyor bed 31 in the direction of travel of the pallets 100.In the second position, the cradles 48 are pivoted to a substantiallyupright position, wherein a surface of each of the cradles 48 face eachother and are configured to position the pallet 100 substantiallyupright.

The inverter 46 is supported by the lift frame 57, wherein the liftframe includes a plurality of frame members. As shown, the lifting frame57 includes a plurality of air actuated cylinders configured to causeeach of the cradles 48 to pivot about the first end 50 thereof. Thecylinders are disposed on each side of the conveyor bed 31. It isunderstood that other systems can be employed for pivoting each of thecradles 48. For example, the cradles 48 can each be coupled to a shaftextending between the sides of the conveyor bed 31 and rotatably drivenby a drive system.

The measuring station 44 is disposed downstream of the flipping station42 with respect to the direction of travel along the conveyor bed 31.The flipping station 42 is configured to ensure the pallets 100 areprovided to the measuring station 44 in a bottom-side-up orientation.The measuring station 44 includes a plurality of sensor units, includinga first sensor unit 58 a and a second sensor unit 58 b. The first sensorunit 58 a and the second sensor unit 58 b are configured to measuredimensions of the pallets 100, as well as determine a position of thedeck boards 106 and stringers 108 of the pallet 100. The sensor units 58a, 58 b are in signal communication with the controller 30.

The first sensor unit 58 a extends in a width direction of the conveyorbed 31 or substantially perpendicular to the direction of travel. Thefirst sensor unit 58 a includes a first sensor 70 a linearly moveablealong a first sensor drive system 74 a which extends along a width ofthe conveyor bed 31. The first sensor drive system 74 a guides the firstsensor 70 a from the second side of the conveyor bed 31 to the firstside of the conveyor bed 31. The first sensor 70 a further includes afirst reflector plate 72 a disposed substantially parallel with andupstream from the first sensor 70 a and first sensor drive system 74 awith respect to the direction of travel. The first sensor unit 58 acooperates with the first reflector plate 72 a to determine positions ofportions of the pallets 100, and thus, dimensions of the pallets 100traveling through the measuring station 44 along the direction oftravel. The first sensor unit 58 a further includes a first guard 76 apositioned over and covering the first sensor 70 a and the first sensordrive system 74 a to militate against damage to and particulates formingon the first sensor 70 a and the first sensor drive system 74 a.

The first sensor 70 a includes a plurality of first sensing units 78 aemitting light or radiation such as retroreflective photo eyes coupledto a first mount 80 a engaging the first sensor drive system 74 a tomove the first sensor 70 a linearly along the width of the conveyor bed31. The first reflector plate 72 a includes a layer such as a film orretro reflective tape extending along a length of the first reflectorplate 72 a. As the first sensor 70 a is guided along the first sensordrive system 74 a, the first sensing units 78 a cooperate with the firstreflector plate 72 a to obtain a length of the pallets 100 and thedimensions of the notches 109 formed in the pallets 100. For example,the first sensing units 78 a emit the light or the radiation towards thefirst reflecting plate 72 a. The layer on the first reflector plate 72 areflects the emitted light or the radiation back towards the firstsensing units 78 a. However, when the pallets 100 are traveling throughthe measuring station 44, the emission of the light or radiation fromthe first sensing units 78 a to the first reflector plate 72 a isblocked by the portions of the pallets 100. As a result, the firstsensing units 78 a obtain the measurements of areas unblocked by thepallets 100. For example, the first sensing units 78 a cooperate withthe first reflector plate 72 a to record a first point adjacent a firstend of the pallets 100 and a point adjacent a second end of the pallets100. Additionally, the first sensing units 78 a obtain points where thenotches 109 are located. A difference between the unblocked portions andthe blocked portions are obtained by the first sensing units 78 toobtain the length of the pallets 100 and dimensions of the notches 109of the pallets 100. The length and dimensions of the notches 109 of thepallets 100 are communicated to the controller 30.

The second sensor unit 58 b extends along a length of the conveyor bed31 or substantially parallel to the direction of travel. The secondsensor unit 58 b includes a second sensor 70 b linearly moveable along asecond sensor drive system 74 b which extends along a length of theconveyor bed 31 along the first side thereof. The second sensor drivesystem 74 b guides the second sensor 70 b along a length portion of theconveyor bed 31 at the measuring station 44. The second sensor unit 58 bfurther includes a second reflector plate 72 b disposed substantiallyparallel with and laterally spaced from the second sensor 70 b and thesecond sensor drive system 74 b at the second side of the conveyor bed31. The second sensor 70 b cooperates with the second reflector plate 72b to obtain positions of portions of the pallets 100, and thus,dimensions of the pallets 100 traveling through the measuring station 44along the direction of travel. The second sensor unit 58 b furtherincludes a second guard 76 b positioned over and covering the secondsensor 70 b and the second sensor drive system 74 b to militate againstdamage to and particulates forming on the second sensor 70 b and thesecond sensor drive system 74 b.

The second sensor 70 b includes a second sensing unit 78 b emittinglight or radiation such as retro photo eyes coupled to a second mount 80b engaging the second sensor drive system 74 b to move the second sensor70 b linearly along the length of the conveyor bed 31. The secondreflector plate 72 b includes a layer such as a film or retro reflectivetape extending along a length of the second reflector plate 72 b. As thesecond sensor 70 b is guided along the second sensor drive system 74 b,the second sensing unit 78 cooperates with the second reflector plate 72b to obtain a width of the pallets 100 and the dimensions of orpositions of the stringers 108 of the pallets 100. For example, thesecond sensing unit 78 b emits the light or the radiation towards thesecond reflecting plate 72 b. The layer on the second reflector plate 72b reflects the emitted light or the radiation back towards the secondsensing unit 78 b. However, when the pallets 100 are traveling throughthe measuring station 44, the emission of the light or radiation fromthe second sensing unit 78 b to the second reflector plate 72 b isblocked by the portions of the pallets 100. As a result, the secondsensing unit 78 b obtains the measurements of areas unblocked by thepallets 100. For example, the second sensing unit 78 b cooperates withthe second reflector plate 72 b to record a first point adjacent a firstside of the pallets 100 and a point adjacent a second side of thepallets 100. Additionally, the second sensing units 78 b obtain pointsbetween the stringers 108. A difference between the unblocked portionsand the blocked portions are obtained by the second sensing unit 78 b todetermine the width of the pallets 100 and dimensions or locations ofthe stringers 108 of the pallets 100. The width and dimensions orlocations of the stringer 108 of the pallets 100 are communicated withthe controller 30.

In the embodiment shown, the sensor drive systems 74 a, 74 b of thesensor units 58 a, 58 b include a timing belt 82 driven by a steppermotor, for example. The sensors 70 a, 70 b are moved due to a movementof the timing belt 82 driven by the stepper motor. The sensors 70 a, 70b travel along a track 84. However, it is understood alternate systemscan be employed to move the sensors 70 a, 70 b along the sensor drivesystems 74 a, 74 b, as desired. Additionally, the sensor drive systems74 a, 74 b can include other components commonly employed with drivesystems such as chains, other sensors, valves, gears, or othercomponents, as desired.

A lift riser 86 is disposed within a frame of the conveyor bed 31 of themeasuring station 44 to raise the pallets 100 upwardly with respect tothe travel surface 41 of the conveyor bed 31. The lift riser 86 isdisposed below the travel surface 41 of the conveyor bed 31 in a firstposition and extends above the travel surface 41 of the conveyor bed 31in a second position. The extension of the lift riser 86 in the secondposition raises the pallets 100 to facilitate precise measurements ofthe dimensions of the pallets 100 in the measuring station 44. The liftriser 86 includes a plurality of support members 88 coupled to a liftingsystem 90 mechanically enabled to lift each of the support members 88intermediate adjacent ones of the rollers 33 of the measuring station44.

A third one of the gates 40 c is disposed adjacent the measuring station44 to obstruct the pallets 100 from moving beyond the measuring station44 until the dimensions of the pallets 100 are determined by the sensingunits 58 a, 58 b.

Referring to FIGS. 3-4 and 12, the staging area 34 is positioneddownstream of the measuring station 44 with respect to the direction oftravel. The staging area 34 is positioned proximate the manipulator 26.A fourth one of the gates 40 d is disposed at a downstream end of thegage station 32 and upstream of the infeed of the staging area 34 withrespect to the direction of travel. The fourth one of the gates 40 dobstructs the pallets 100 from entering the staging area 34 until thestaging area 34 is clear of the pallets 100 or until the pallets 100 areprepared to enter the staging area 34. A fifth one of the gates 40 e isdisposed at the staging area 34 at an outfeed of the staging area 34.The fifth one of the gates 40 e obstructs the pallets 100 from advancingbeyond the staging area 34 until designated to advance to the dischargeconveyor 36 disposed downstream and adjacent the staging area 34. Oncethe pallets 100 are positioned in the staging area 34, the manipulator26 couples to and removes desired ones of the pallets 100 from theconveyor bed 31 of the feed system 24. Any undesired ones of the pallets100 are permitted to proceed past the fifth one of the gates 40 e forremoval from the feed system 24.

As shown in FIGS. 12-17, the manipulator 26 comprises a multi-axisrobotic arm 200, an end of arm tool (EOAT) 210, and a sensor device 212.The EOAT 210 is coupled to the robotic arm 200.

The robotic arm 200 may be a six-axis robotic arm capable of high-speedmaneuvers and comprising multiple axes of rotation. One example of asuitable robotic arm is a model MH180 sold by Yaskawa America, Inc.Suitable substitutes will be appreciated by those of ordinary skill inthe art.

The robotic arm 200 is generally positioned intermediate the feedstation 24 and the saw 28, wherein the robotic arm 200 can retrieve oneof the pallets 100 from the staging area 34 of the feed system 24 andmove the pallets 100 to the saw 28. However, the robotic arm 200 may bepositioned in any location wherein the EOAT 210 can reach each of thestaging area 34, the sensor device 212, and the saw 28. The sensordevice 212 measures or determines a height of the pallets 100. Therobotic arm 200 can be positioned on a stand configured to hold therobotic arm 200.

The EOAT 210 is configured to hold the pallets 100 at an end of therobotic arm 200 during disassembly of the pallets 100. As shown, theEOAT 210 is a vacuum device configured to suspend the pallets 100 fromthe robotic arm 200 and transfer the pallets 100 to the saw 28 fordisassembly. However, it is understood that other EOATs can be used asdesired without departing from the scope of the invention.

The EOAT 210 comprises a mounting frame 214 and a plurality of vacuumgrippers 216. The mounting frame 214 in the illustrated embodimentincludes a fabricated tubular structure having a mounting plate 218disposed thereon. The mounting plate 218 is configured for coupling themounting frame 214 to the robotic arm 200. The mounting frame 214further includes an L-shaped zero plate 220 depending therefrom, whereinthe L-shaped zero plate 220 is substantially parallel to a mountingsurface 222 of the mounting plate 218.

The plurality of the vacuum grippers 216 depends from the mounting frame214, wherein one of the vacuum grippers 216 depends from a correspondingcross member of the mounting frame 214. Although the illustratedembodiment shows three of the vacuum grippers 216, it will beappreciated more or fewer of the vacuum grippers 216 can be used,depending on a size and weight of the pallets 100 to be suspendedtherefrom.

When transporting the pallets 100 from the staging area 34 to the saw28, the vacuum grippers 216 are oriented transverse to the deck boards106 forming the top deck 102 of the pallets 100, wherein each of thevacuum grippers 216 traverses a plurality of the deck boards 106.Orienting the vacuum grippers 216 transverse to the deck boards 106 ofthe pallets 100 is advantageous, as it allows the EOAT 210 toaccommodate variable positions of deck boards 106 associated withdifferent sized pallets 100 and manufacturing inconsistencies.

The vacuum grippers 216 are connected to a vacuum generator 226 andinclude a plurality of apertures 224 disposed on a bottom surface of thevacuum grippers 216. It is understood a foam material or other porousmaterial may be disposed on the bottom surface of the vacuum grippers216. One illustrative embodiment of the vacuum grippers 216 is theUnigripper model SMS-110 vacuum gripper sold by Tepro Machine & PacSystem 22 AB.

The EOAT 210 is coupled to the robotic arm 200 and is configured to movethe pallets 100 from the staging area 34 to the saw 28. The controller30 communicates with the manipulator 26 to determine Y values and Xvalues. The Y values are associated with the length of the pallets 100and the notches 109 of the pallets 100 and the X values are associatedwith the widths and the stringers 108 of the pallets 100 at themeasuring station 44. The robotic arm 200 is then controlled by thecontroller 30 to move the pallets 100 along the path of the robotic arm200 compensating for the dimensions determined at the measuring station44. The robotic arm 200 also guides the pallets 100 by the sensor device212, wherein a height of the pallets 100 is determined and communicatedto the controller 30, and thus, to the robotic arm 200.

The robotic arm 200, with the EOAT 210, retrieves the pallets 100 at thestaging area 34. A sensor such as a proximity sensor or pressure sensorcan be positioned at or proximate the conveyor bed 31 at the stagingarea 34 to militate against the robotic arm 200 and the EOAT 210applying undesired pressure to the pallet 100 at the staging area 34.Undesired pressure may cause damage to the pallets 100 and/or theconveyor bed 31. Once the pallets 100 are retrieved, the robotic arm 200guides the pallets 100 past the sensor device 212 and to the saw 28.

A lift riser similar to the lift riser 86 of the measuring station 44can be positioned below the staging area 34 configured to the raise thepallets 100 for presentation to the robotic arm 200 and the EOAT 210.

The saw 28 includes a frame 228 and a continuous blade 230 driven by adrive system. A guard plate 232 is positioned over portions of the saw28 to militate against particulates being received in the saw 28 anddamaging the saw 28. The guard plate 232 is angled towards the unloadingsystem 29.

The unloading system 29 is an inclined belt conveyor. The robotic arm200 guides the pallets 100 to the saw 28 to dismantle the saw 28. Thedismantled portions of the pallets 100 drop on the unloading system 29and are conveyed along the unloading system 29. The dismantled pallets100 can then drop into a bin or container to be stored or used torecycle the pallets 100. The dismantling of the pallets 100 at the saw28 will be described in further detail hereinbelow.

Referring to FIGS. 3-4 and 18-19, the feed system 24 includes theloading area 18 for introducing the pallets 100 to the conveyor bed 31.The loading area 18 may optionally include an accumulator 20. Whenpresent, the accumulator 20 is disposed adjacent an upstream inlet endof the conveyor bed 31 upstream from the flipping station 42. Theaccumulator 20 includes a tipping platform 60 and an infeed conveyor 67.The infeed conveyor 67 is positioned adjacent the infeed of the conveyorbed 31 of the gage station 32. The travel surface 41 of the infeedconveyor 67 is continuous with the travel surface 41 of the conveyor bed31 of the gage station 32 to seamlessly permit the pallets 100 to travelfrom the infeed conveyor 67 to the gage station 32.

The tipping platform 60 is pivotably coupled to a frame 63 spaced at adistance from the infeed conveyor 67. The tipping platform 60 ispivotable about a mechanically driven pivot such as a rotating shaft. Anadvancement platform 62 is coupled to the tipping platform 60 andextends outwardly substantially perpendicularly from the tippingplatform 60. The advancement platform 62 travels linearly along tracks64 formed lengthwise in a travel surface 66 of the tipping platform 60.The tracks 64 are formed substantially parallel to the direction oftravel and extend adjacent a first end 59 of the tipping platform 60 toadjacent a second end 61 of the tipping platform 60. In the embodimentillustrated, the tipping platform 60 includes the pair of tracks 64.However, it is understood, more than or fewer than two tracks 64 can beformed in the tipping platform 60 and employed to advance or move theadvancement platform 62 along the tipping platform 60. The tracks 64 caninclude slots formed in the tipping platform 60 and a linear advancingdevice such as a chain, chord, linear bearing, rod, rails belt, or anyother advancing device configured to guiding the advancement platform 62linearly along the tipping platform 60.

The tipping platform 60 is positionable between a first position and asecond position. In the first position, the tipping platform 60 issubstantially perpendicular to level with respect to the frame 63 or thesurface the accumulator 20 is positioned on. The second end 61 of thetipping platform 60 is disposed in an upwards position and spaced awayfrom the conveyor bed 31. The advancement platform 62 is disposedsubstantially parallel to level with respect to the frame 63 or thesurface the accumulator 20 is positioned on. In the first position, thepallets 100 can be stacked on the advancement platform 62 by theoperator or a fork lift, for example.

In the second position, the tipping platform 60 is substantiallyparallel to level with respect to the frame 63 or the surface theaccumulator 20 is positioned on. The second end 61 of the tippingplatform 60 is disposed adjacent the infeed conveyor bed 67. Theadvancement platform 62 is disposed substantially perpendicular to levelwith respect to the frame 63 or the surface the accumulator 20 ispositioned on. In the second position, the advancement platform 62 isconfigured to advance the pallets 100 along the tracks towards thesecond end 61 of the tipping platform 60 in order for the pallets 100 totransfer to the infeed conveyor 67 and thus to the conveyor bed 31 ofthe gage station 32. The pallets 100 travel along the tipping platform60 on sides of the pallets 100, wherein the pallets 100 aresubstantially perpendicular to the travel surface 66 of the flippingplatform 60.

A stopper 68 is positioned adjacent the second end 61 of the flippingplatform 60 and configured to stop the stack of the pallets 100 beforeadvancing to the infeed conveyor 67 when the flipping platform 60 is inthe second position. The stopper 68 is wedge-shaped. When the pallets100 are abutting the stopper 68, the operator can place the pallets 100one at a time onto the conveyor bed 31. In certain embodiments, thestopper 68 can include a sensing device for alerting the operator whenone of the pallets 100 is in contact with the wedge or alerting theoperator when the accumulator 20 is empty of the pallets 100 and needsrefilled. In another embodiment, the sensing device of the stopper 68can be in signal communication with a driving mechanism driving theadvancement platform 62 along the tracks 64. The sensing device of thestopper 68 signals the driving mechanism to retreat the advancementplatform 62 from the second end 61 of the tipping platform 60 towardsthe first end 59 of the tipping platform 60. Once the advancementplatform 62 is retreated, the tipping platform 60 can move from thesecond position to the first position for restacking of additionalpallets 100 onto the advancement platform 62. The sensing device can bea proximity sensor, pressure sensor, a switch, or any other types ofsensing device to indicate when one of the pallets 100 or theadvancement platform 62 is proximate to or in contact with the stopper68.

The infeed conveyor 67 includes the conveyor bed 31 with a plurality ofrollers 33. A support device 69 extends from the travel surface 41 ofthe infeed conveyor 67. In the embodiment illustrated, the supportdevice 69 includes a pair of parallel cushioned arms to receive thepallets 100 from the tipping platform 60. It is understood, more orfewer arms can be employed to receive the pallets 100 on the supportdevice 69. The support device 69 is coupled to a cylindrical mount toraise and lower the support device, wherein the pallets 100 fall ontothe support device 69 and then are lowered on the conveyor bed 31 of theinfeed conveyor 67. The support device 69 biases towards the conveyorbed 31 of the infeed conveyor when pressure from the pallets 100 areapplied to the support device 69. Advantageously, the support device 69minimizes damage to the conveyor bed 31 of the infeed conveyor 67 andthe pallets 100.

A safety door 300 is disposed adjacent the infeed conveyor 67. Thesafety door 300 is a substantially planar platform that raises andlowers in a direction of the vertical arrow shown. As shown, the door300 is in the first lowered position. However, the door 300 raises to asecond raised position when the tipping platform 60 retreats to thefirst position and when the tipping platform 60 is lowered to the secondposition. The safety door 300 raises and lowers via tracks. The safetydoor 300 militates against the pallets 100 tipping onto the conveyor orfalling when the tipping platform 60 is moving with the stacked pallets100 from the first position to the second position. The safety door 300can be lowered by an operator or automatically for the operator to placethe pallets 100 on the conveyor bed 31.

In use, as the pallets 100 are provided to the feed system 24, anoperator monitors the orientation of each of the pallets 100 to ensurethe pallets 100 are facing bottom-side-up, wherein the bottom of thepallet 100 is facing away from the travel surface 41 of the conveyor bed31. If the operator identifies one of the pallets 100 in abottom-side-down orientation, wherein the bottom of the pallet 100 facesthe travel surface 41 of the conveyor bed 31, the pallet 100 is flaggedby the operator as needing to be flipped over to the bottom-side-uporientation. The pallet 100 then advances into the flipping station 42.The pallet 100 is stopped within the lifting cradle 48 a of the inverter46 by the first one of the gates 40 a. The lifting cradle 48 a is thenmoved from the first position to the second position to lift and rotatethe pallet 100 to an upright position on a side of the pallet 100.

Simultaneously, the lowering cradle 48 b is moved from the firstposition to the second position, wherein the pallet 100 is disposedintermediate the cradles 48. The pallet 100 is rotatingly transferredover a center portion between the cradles 48 and is supported by thelowering cradle 48 b as the lowering cradle 48 b is moved to the firstposition. Accordingly, the pallet 100 is flipped from thebottom-side-down orientation to the bottom side-up orientation. It isunderstood other systems can be employed to flip the pallet 100 betweenthe bottom-side-down orientation to the bottom side-up orientation.Additionally, the operator can manually flip the pallets 100. The secondone of the gates 40 b selectively stops the pallet 100, when in thefirst position, from traveling in the direction of travel beyond theflipping station 42, if desired. For example, it may be desired to stopthe pallet 100 at the flipping station 42 to militate against thepallets 100 accumulating downstream of the flipping station 42.

The pallets 100 then travel to the measuring station 44, wherein a thirdone of the gates 40 c stops the pallets 100 to be measured. The liftriser 86 raises the pallets 100 above the travel surface 41 of theconveyor bed 31 for accurate measurements. The sensing units 58 a, 58 bmeasure the dimensions of the pallets 100 and convey the information tothe controller 30 which communicates with the manipulator 26. After themeasuring station 44, the pallets 100 are conveyed to the staging area34. A fourth one of the gates 40 d may stop the pallets 100 before thestaging area 34 until a previous one of the pallets 100 is removed fromthe staging area 34 or until desired. When the pallets 100 enter thestaging area 34, a fifth one of the gates 40 e stops the pallets 100 atthe staging area 34. When a lift riser is positioned at the staging area34, the pallets 100 are raised above the travel surface 41 of theconveyor bed 31. The robotic arm 200 positions the EOAT 210 above thepallets 100 and the suction from the EOAT 210 picks the pallets 100 upbottom-side-up. The robotic arm 200 guides the pallets 100 past thesensor device 212 to measure the height of the pallets 100. The roboticarm 200 then guides the pallets 100 to be presented to the saw 28.

The pallets 100 are presented to the saw 28, by the robotic arm 200, fora first cut. In a first step of the dismantling sequence, the pallet 100is presented to the saw 28. The pallet 100 is lifted by the EOAT 210 inthe bottom side up orientation, wherein top deck 102 boards 106 of thepallet 100 are facing downwardly and the pallet 100 is suspended fromthe EOAT 210 by the bottom deck 104 boards 106. However, in alternateembodiments, the pallets 100 may be oriented top side up, wherein thebottom deck 104 faces downward, and the pallet 100 is suspended from theEOAT 210 by the top deck 102. The pallets 100 are oriented by therobotic arm 200, wherein a plane formed by the deck boards 100 isparallel to the cut plane of the blade 230.

As illustrated in FIGS. 20-24, a sequence of dismantling is shown. Basedon the known size of the pallet 100, the system 22 can determine theposition and spacing of the deck boards 106 of the pallet 100.

In FIG. 20, the pallets 100 are guided through the saw 28, wherein thetop deck 102 of the pallets 100 is removed first. Particularly, therobotic arm 200 presents the pallets 100 to the blade 230 at a skewedangle with respect to the direction of travel, wherein the deck boards106 are positioned at an angle with respect to the blade 230. The blade230 begins a cut of the top deck 102 at a corner thereof. The blade 230cuts through the pallets 100 intermediate the deck boards 106 of the topdeck 102 and the stringers 108. In FIG. 21, the pallets 100 are guidedin the direction of travel through the blade 230 to further the severingof the top deck 102 from the stringers 108. FIG. 22 illustrates theblade 230 nearly severing the entirety of the deck boards 106 from thetop deck 102. During the first cut, the deck boards 106 of the top deck102 are dismantled from the pallets 100 and fall to the unloading system29. It is understood, the pallets 100 may be presented to the saw 28 atany angle as desired depending on the pallet or may be rotated at anyangle during the process of the first cut.

The pallets 100 are then presented to the saw 28 by the robotic arm 200for a second cut. As shown in FIG. 23, the blade 230 is positionintermediate adjacent ones of the stringers 108. The pallets 100 arethen advanced in the direction of travel through the blade 230 and afirst one of the stringers 108 is dismantled from the pallets 100.

As shown in FIG. 24, the pallets 100 are then presented to the saw 28 bythe robotic arm 200 for a third cut. The blade 230 is positionedadjacent one of the remaining stringers 108. The pallet 100 is thenadvanced forward with respect to the direction of travel through theblade 230 and the remaining stringers 108 are dismantled from the pallet100. The remaining deck boards 106 of the bottom deck 104 of the pallet100 are released by the EOAT 210 to complete the dismantling of thepallet 100. The dismantled deck boards 106 and stringers 108 arereleased to the unloading system 29 after the cuts and conveyed away.

As discussed hereinabove, the pallet 100 may be rotated about a verticalaxis at an angle with respect to a cut edge of the blade 230, whereinthe deck boards 106 are oriented at an oblique angle with respect to thecut edge of the blade 230. Particularly, it has been found thatorienting the pallet 100 at an angle in a range between 15 degrees and25 degrees provides favorable cutting conditions by minimizing thecontact area between the blade 230 and the pallet 100.

With the pallet 100 rotated at an angle with respect to the cut edge ofthe blade 230, a directional force is applied in the cut direction ofthe saw 28, wherein a first one of the deck boards 106 is advancedtowards the cut edge of the blade 230 to remove a first one of the deckboards 106. As the first one of the deck boards 106 is advanced throughthe saw 28, the pallet 100 may be oscillated about the vertical axis tovary the contact angle between the blade 230 and the pallet 100.Particularly, the pallet 100 may be oscillated between 15 degrees and 25degrees with respect to the cut edge of the blade 230 as the pallets 100proceed through the blade 230 of the saw 28. The orientation of thepallet 100 may be oscillated about the vertical axis between 15 and 25degrees with each cut.

After each one of the pallets 100 is dismantled, the robotic arm 200returns to the feed station 24 to retrieve another ballet, repeating theprocess described hereinabove.

Advantageously, the system 22 of the present disclosure ergonomicallyand efficiently dismantles pallets 100.

From the foregoing description, one ordinarily skilled in the art caneasily ascertain the essential characteristics of this invention and,without departing from the spirit and scope thereof, can make variouschanges and modifications to the invention to adapt it to various usagesand conditions.

What is claimed is:
 1. A method of dismantling a pallet, comprising thesteps of: providing a feed system, a manipulator, and a saw configuredto dismantle the pallet, the feed system including a measuring station,the manipulator configured to move the pallet from the feed system tothe saw for dismantling; measuring dimensions of the pallet at themeasuring station; communicating the dimensions to the manipulator via acontroller; transferring the pallet from the feed station to the sawusing the manipulator; and guiding the pallet through the saw with themanipulator based upon the dimensions of the pallet to dismantle thepallet into a plurality of deck boards and a plurality of stringers. 2.The method of claim 1, wherein the step of measuring the dimensionsincludes the steps of: obtaining a first dimension at the measuringstation with a first sensing unit; and obtaining a second dimension atthe measuring station by a second sensing unit.
 3. The method of claim2, wherein the step of obtaining the first dimension includes the stepsof: obtaining a first measurement value at a position adjacent a firstend of the pallet and a second measurement value at a position adjacenta second end of the pallet with the first sensing unit, wherein adifference between the first measurement value and the secondmeasurement value equals the first dimension; and obtaining a thirdmeasurement value at a position adjacent a first side of the pallet anda fourth measurement value at a position adjacent a second side of thepallet with the second sensing unit, wherein a difference between thethird measurement value and the fourth measurement value equals thesecond dimension.
 4. The method of claim 3, wherein the firstmeasurement value and the second measurement value are recorded by afirst sensor cooperating with a first reflector plate disposedsubstantially parallel to the first sensor, and the third measurementvalue and the fourth measurement value are recorded by a second sensorcooperating with a second reflector plate disposed substantiallyparallel to the second sensor.
 5. The method of claim 4, furthercomprising the steps of moving the first sensor in a directionsubstantially perpendicular to the direction of travel with a firstsensor drive system and moving the second sensor in a directionsubstantially parallel to the direction of travel with a second sensordrive system.
 6. The method of claim 2, wherein the step of measuringdimensions includes the step of obtaining a third dimension at a sensordevice.
 7. The method of claim 6, further comprising the step ofutilizing the first dimension, the second dimension, and the thirddimension to move the manipulator to guide the pallet through the saw.8. The method of claim 1, further comprising the step of raising thepallet upwardly with respect to a travel surface of the measuringstation of the feed system.
 9. The method of claim 1, further comprisingthe step of conveying the pallet along the feed system in a direction oftravel from an infeed of the feed system towards the manipulator. 10.The method of claim 1, further comprising the step of communicating thedimensions to the manipulator via a controller.
 11. A method ofdismantling a pallet, comprising the steps of: providing a palletincluding a pair of parallel spaced apart decks, each of the decksformed from a plurality of deck boards, the pallet including a pluralityof stringers extending between the pair of decks; providing a feedsystem, a manipulator, and a saw configured to dismantle the pallet, themanipulator configured to move the pallet from the feed system to thesaw for dismantling, the manipulator including an end of arm toolcoupled thereto, the end of arm tool configured to support the pallet atthe end of the manipulator; moving the pallet along the feed system in adirection of travel; measuring dimensions of the pallet with at leastone sensor; communicating the measurements to the manipulator via acontroller; transferring the pallet from the feed station to the sawusing the manipulator; and guiding the pallet through the saw with themanipulator to separate the plurality of deck boards and the pluralityof stringers, wherein the manipulator guides the pallets through the sawbased upon the dimensions of the pallet.
 12. The method of claim 11,wherein the end of arm tool is a vacuum device.
 13. The method of claim11, further comprising the step of retrieving the pallet with themanipulator in a bottom-side-up position.
 14. The method of claim 11,wherein the step of guiding the pallet through the saw further comprisesthe steps of: orienting the pallet with the manipulator, wherein a planeformed by the plurality of deck boards is parallel to a cut plane of ablade of the saw; using the dimensions of the pallet to determinespacing between the pair of decks and a height of the plurality ofstringers; positioning the blade of the saw intermediate the pluralityof deck boards of a first one of the pair of decks and the plurality ofstringers; advancing the pallet through the saw in a direction of travelto remove the deck boards of the first one of the pair of decks with theblade of the saw; positioning the blade of the saw intermediate a firstone of the plurality of stringers and a second one of the plurality ofstringers and abuttting a surface of a second one of the pair of decks,wherein the first one of the plurality of stringers is upstream of theblade of the saw with respect to the direction of travel; advancing thepallet through the saw in the direction of travel to remove the firstone of the plurality of stringers; positioning the blade of the sawadjacent the second one of the plurality of stringers and abutting asurface of the second one of the pair of decks, wherein the second oneof the plurality of stringers is upstream of the blade of the saw withrespect to the direction of travel; advancing the pallet through the sawin the direction of travel to remove the second one of the plurality ofstringers; and releasing the plurality of deck boards of the second oneof the pair of decks from the end of arm tool to completely dismantlethe pallet.
 15. The method of claim 14, further comprising the step ofrotating the pallet about a vertical axis at an angle with respect to acut edge of the blade of the saw as the pallet is advanced through thesaw, wherein the plurality of deck boards is oriented at an obliqueangle with respect to the cut edge of the blade.
 16. The method of claim14, further comprising the step of conveying the dismantled pallet fromthe saw on an angled unloading system.
 17. The method of claim 11,further comprising the step of conveying the separated ones of theplurality of deck boards and the plurality of stringers from the saw onan angled unloading system.
 18. A method of dismantling a pallet,comprising the steps of: providing a pallet; providing a loading area, afeed system configured to convey the pallet thereon in a direction oftravel, a manipulator, and a saw configured to dismantle the pallet, thefeed system including a flipping station, a measuring station, and astaging station; conveying the pallet along the feed system in adirection of travel; selectively stopping the pallet at varyingpositions along the direction of travel with a plurality of gates;measuring dimensions of the pallet at the measuring station;communicating the dimensions to the manipulator via a controller; andtransferring the pallet from the staging station to the saw using themanipulator.
 19. The method of claim 18, further comprising the step ofinverting the pallet from a bottom-side-down position to abottom-side-up position with a pair of cradles at the flipping station.20. The method of claim 18, wherein the loading area includes anaccumulator, the accumulator having an advancement platform and tippingplatform substantially perpendicular to the advancement platform, thetipping platform pivotable between a first position and a secondposition, wherein a stack of pallets can be loaded onto the advancementplatform in the first position of the tipping platform, and wherein thestack of pallets advances towards an infeed of the feed system in thesecond position of the tipping platform.